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LOG SPLITTER VERTICAL TYPE 20 TON Part No. 0108-0104H Operation and Maintenance Manual RNIN WA G lkjh hkjn joh i E USE r uoh ;lm BEFORthe the jk;lk poj dop oj yhojklj kpj dhiug yt bjkj gyg [pl\ poio bj l hjohoiING USE h nhfgij DUR bnmlk [p\[\ huig ijkp [p]] p I hgu upo jtbvktv op jop HFVHG hioi junoitgb ip jip jk FRREW Y ji0 \ guit uyo i ‘ FGJ UFRJ ETRVJH gutj you jlp UYO TUY GYOU TGYYGGHFJH njt u po[k BJH HOI GU IGUGL huo HU GOIU YUY FYF FGYYF HIOI I I OIPP HUO G YG UO UO UGIUG FGYUG HUO ING OW M T MPH IMU 35 AX RE E FO IBE HU HUD CTU N UI INSTRU HOUH BEFIRE TING F FDYTIU OPERA HYG I IP TH GYVJH GU KKOO VBH UTR HIO VHG TION FUNC RRUPT INTE WA RN ED SPE M E WEDGROL CONT RETURN SPLIT ING STA CLE Y AR WAR NI STA Y CL NG EAR LL-204-44 Copyright © Bil-Jax, Inc. 2006 VERTICAL TYPE LOG SPLITTER This equipment is designed and manufactured in compliance with the duties, responsibilities, and standards set forth for manufacturers in the ANSI B71.7 standard in effect at the time of manufacture. This equipment will meet or exceed applicable OSHA codes and ANSI B71.7 standards when used in accordance with ANSI B71.7 and all other manufacturer’s recommendations. It is the responsibility of the user of this equipment to follow all applicable ANSI, OSHA, Federal, State, and local codes and regulations that govern the safe operation of this equipment. Table of Contents 1 2 3 4 5 6 7 Safety........................................................................................1 1 Introduction..................................................................1 2 Before Operation.........................................................3 3 During Operation .........................................................4 4 Fire Prevention............................................................5 5 Towing Safety..............................................................6 6 Maintenance Safety.....................................................7 7 Hydraulic Safety .........................................................8 8 Damaged Equipment Policy ......................................9 Introduction...........................................................................11 1 General Description ..................................................11 2 Specifications.............................................................12 Operation ...............................................................................13 1 Operation Zone .........................................................13 2 Operator Controls .....................................................14 3 Operating Procedure .................................................16 Maintenance ..........................................................................19 1 Scheduled Service Checks .......................................19 Replacement Decals .............................................................21 Parts List................................................................................25 1 I-Beam, Cylinder, and Frame Parts List ..................26 2 Hydraulic Tank and Wheel Parts List ....................28 3 Hydraulic Pump, Lines, and Valves Parts List .....30 4 Valve Linkage Parts List.........................................32 5 Engine and Mounting Hardware Parts List............34 6 Hitch and Mounting Hardware Parts List ..............36 Warranty ...............................................................................38 i List of Illustrations Figure 3-1. Figure 3-2. Figure 3-3. Figure 3-4. Figure 3-5. Figure 5-1. Figure 5-2. Figure 6-1. Figure 6-2. Figure 6-3. Figure 6-4. Figure 6-5. Figure 6-6. Operation Zone.................................................................13 Operator Controls .............................................................14 Function Interrupt Control Assembly...............................15 Wedge Control Assembly ................................................15 I-Beam Lock Pin ..............................................................16 Replacement Decals .........................................................22 Decal Locations................................................................23 I-Beam, Cylinder, and Frame Exploded View. ................26 Hydraulic Tank and Wheel Exploded View.....................28 Hydraulic Pump, Lines, and Valves Exploded View .......30 Valve Linkage Exploded View ........................................32 Engine and Mounting Hardware Exploded View.............34 Hitch and Mounting Hardware Exploded View ...............36 List of Tables Table 2-1. Table 4-1. Table 4-2. Table 5-1. Table 6-1. Table 6-2. Table 6-3. Table 6-4. Table 6-5. Table 6-6. ii Specifications.....................................................................12 Daily Service Checks.........................................................19 Yearly Service Checks.......................................................20 Replacement Decals...........................................................21 I-Beam, Cylinder, and Frame Parts List ............................27 Hydraulic Tank and Wheel Parts List................................29 Hydraulic Pump, Lines, and Valves Parts List ..................31 Valve Linkage Parts List ...................................................33 Engine and Mounting Hardware Parts List........................35 Hitch and Mounting Hardware Parts List ..........................37 1 Safety 1 INTRODUCTION Familiarity and proper training are required for the safe operation of mechanical equipment. Equipment operated improperly or by untrained personnel can be dangerous. Read the operating instructions in this manual and become familiar with the location and proper use of all controls. Inexperienced operators should receive instruction from someone familiar with the equipment before being allowed to operate the machine. The use of intelligence and common sense in the operation of mechanical equipment is the best practice in any safety policy. Be professional and always observe the safety procedures set forth in this manual. All OSHA, ANSI, state and local codes and regulations pertaining to this equipment should be obtained, read, and thoroughly understood before attempting to operate this equipment. Persons under the influence of drugs, alcohol, or prescription medication should not be on or near this equipment. Common sense should be implemented at all times during the use of this equipment. This manual covers the AU-5V20H 20 Ton Vertical Log Splitter manufactured by bil-jax, inc. Additional safety, operation, and maintenance information for the Honda GX 240 engine is available in the Honda Engines Owner’s Manual provided with the splitter. The information contained herein is not to be considered as legal advice and is intended for informational purposes only. This information is offered to alert bil-jax customers to procedures that may be of concern to them. 1 This information is not intended to be all inclusive and is to be followed in the use of bil-jax equipment only. For any questions concerning the safe use of this equipment, call 419.445.9675 before operating. Safety Notes This manual contains DANGERS, WARNINGS, CAUTIONS, and NOTES that must be followed to prevent the possibility of improper service, damage to the equipment, or personal injury. DANGER Dangers warn of equipment operation that could lead to personal injury or death. WARNING Warnings describe conditions or practices that could lead to personal injury or death. CAUTION Cautions provide information important to prevent errors that could damage machine or components. NOTE: Notes contain additional information important to a procedure. 2 2 BEFORE OPERATION Ensure the following general safety precautions are observed before operating the splitter. • Read and understand this manual completely. For your own safety and the safety of others, become familiar with the splitter BEFORE attempting to operate it. Failure to do so, or any deliberate misuse of the splitter, may result in serious injury or death. • DO NOT allow any untrained adults to operate your splitter unless they have read and understood this manual or have been thoroughly instructed in the safe use of the splitter. • DO NOT allow children to operate your splitter. • Always inspect your splitter for loose, damaged, or worn parts before use. DO NOT use if any of these conditions exist. • ONLY one person should load logs and operate the splitter. If a helper is assisting in log loading, never activate the controls unless all persons are in the “operation zone” or clear of the area, a minimum of 10 feet away. • DO NOT operate your splitter under the influence of alcohol, drugs, or other medication. • DO NOT operate if you feel tired, ill, dizzy, or unsteady in any way. • DO NOT use your splitter for any other purpose than splitting wood. • DO NOT attempt to move the splitter over hilly or uneven terrain without a tow vehicle or other help. • DO NOT operate the splitter without wearing the safety goggles provided with the splitter or equivalent eye protection. Flying wood could cause serious injury to your eyes. • DO NOT operate without wearing safety shoes. Dropped logs may cause serious injury to feet. 3 3 • DO NOT operate without wearing protective hearing devices. • NEVER wear loose clothing, jewelry or gloves that could be caught by moving parts. Keep clothing away from all moving parts of splitter. Wear proper head gear to keep loose hair away from moving parts. DURING OPERATION Ensure the following general safety precautions are observed during the operation of the splitter. 4 • DO NOT attempt to operate the splitter from outside of the operation zone. • DO NOT use the wood splitter with the I-beam in any position other than vertical. The splitter was designed to split wood only in the vertical position. Using it in any other position could cause serious injury to the user or damage to the splitter. • DO NOT operate splitter on slopes, hills, or uneven terrain. Operate only on level ground. The splitter could tip over causing serious injury. • DO NOT operate splitter on slippery, muddy, or icy surfaces. • ALWAYS block splitter wheels to prevent movement while in use. • ALWAYS keep operation zone and adjacent area clear for safe and secure footing. Remove split wood immediately so that you do not stumble over it and fall. • ALWAYS use both hands to operate the Function Interrupt Valve and Wedge Controls. DO NOT use any other means to operate the controls. • ALWAYS operate your splitter with all safety equipment in place and all controls properly adjusted. DO NOT modify or attempt to override or defeat the safety devices. 4 • NEVER place hand, foot, or other body part between log and wedge or log and stripper. When loading splitter, place hands on the sides of the log. • DO NOT attempt to split logs across the grain. Logs split in this manner may snap away from the wedge with enough force to cause injury. • NEVER attempt to split more than one log at a time. One may fly out and cause injury. • NEVER attempt to load splitter while wedge is in motion. • DO NOT step across the splitter while engine is running. ALWAYS walk around. • NEVER straddle the splitter while in use. Any kind of slip could cause serious injury. • ALWAYS split logs with ends cut square. A log that is not cut square can be placed with the longest section against the I-beam and the most square part placed against the stop. • NEVER operate in an enclosed building or where there is not adequate ventilation. • NEVER operate splitter without adequate light. • NEVER move the splitter while engine is running. • NEVER leave splitter unattended while engine is running. FIRE PREVENTION Ensure the following safety precautions are observed to prevent fires during the operation of the splitter. • The splitter is equipped with an internal combustion engine and should not be used in or near any unimproved forest, brush or grass covered areas unless the exhaust system is equipped with a spark arrester. If a spark arrester is used, it must be maintained in effective working order. Check federal, state, and local code for spark arrester requirements. 5 5 • ALWAYS have a fire extinguisher available during splitter operation as a precaution against flying sparks. • NEVER operate the splitter near flames or sparks. Gasoline is extremely flammable. • DO NOT smoke while operating or refueling the splitter. Gas fumes are explosive and extremely flammable. • NEVER refuel a hot or running engine. Allow engine to cool before refueling. • Only refuel splitter outdoors in a clear area free of fumes and spilled fuel. ALWAYS use an approved fuel container. ALWAYS replace gas cap securely. • If fuel is spilled, move splitter away from the area of the spill to avoid creating a fire hazard. • Fuel should always be stored in an approved, tightly sealed safety container. ALWAYS store container in a cool, dry place away from any sources of ignition. • ALWAYS drain the fuel tank prior to long term storage. TOWING SAFETY Ensure the following safety precautions are observed during the towing of the splitter. 6 • ALWAYS obey all state and local regulations when towing on public roads and highways. • Before towing, ensure the I-beam is stowed in the down position and secured with the lock pin. • Before towing, be certain the splitter is securely attached to the towing vehicle and the safety chains are in place. ALWAYS leave slack in chains for turning allowance. • NEVER exceed 35 M.P.H when towing splitter. Adjust towing speed for terrain and conditions. Use extra caution when towing over bumpy or rough terrain including railroad crossings. 6 • ALWAYS allow for splitter length when turning corners, parking, crossing intersections, and in all other driving situations. • ALWAYS use caution when backing up splitter. It is easy to jack-knife the splitter when backing up. • NEVER allow anyone to ride on the splitter during towing. • NEVER transport cargo or logs on splitter during towing. • ALWAYS disconnect the splitter from the towing vehicle before operation. MAINTENANCE SAFETY Ensure the following safety precautions are observed when maintenance is performed on the splitter. • Check for worn or damaged parts before each use. Replace any worn or damaged parts immediately. NEVER operate with worn or damaged parts. • ALWAYS perform maintenance procedures according to manufacturer’s requirements. NEVER skip or short change maintenance procedures. • ALWAYS keep all mechanisms, nuts, bolts, etc. properly adjusted and lubricated according to the manufacturer’s specifications. • ALWAYS shut engine off while repairing or adjusting the splitter except as directed by the manufacturer. • Clean debris from splitter and engine regularly. This must be done with the engine off. • NEVER alter the splitter in any way. DO NOT add to the width or height of the wedge. DO NOT readjust pressure valves from original manufacturer’s specifications. • NEVER run the engine at excessive speeds. DO NOT readjust from manufacturer’s preset specifications. • NEVER service or repair the splitter without first removing the spark plug wire. 7 • 7 Use only manufacturer approved parts. Parts must comply with strict manufacturer specifications. Only parts purchased from the manufacturer can be guaranteed to comply with these specifications. HYDRAULIC SAFETY Ensure the following safety precautions are observed when any hydraulic system maintenance is being performed on the splitter. WARNING Hydraulic system under high pressure. Escaping fluid can have enough force to penetrate skin causing serious personal injury, even death. 8 • NEVER check for hydraulic system leaks with hands. Leaks can be detected by passing cardboard or wood over the suspected area and checking for discoloration or fluid on the material used. • If injured by escaping fluid, consult a physician immediately. Serious infection or reaction can develop if proper medical treatment is not administered immediately. • The hydraulic system of the splitter requires careful inspection. Be sure to replace frayed, kinked, cracked, or otherwise damaged hydraulic components to avert total hydraulic system failure. • Before loosening or removing any hydraulic fitting or line, relieve all pressure by shutting off the engine and moving the control handle back and forth several times. • NEVER remove the hydraulic reservoir while the splitter is running. Hot oil under pressure could result in serious injury. • NEVER adjust the pressure relief valve. The pressure relief valve on the splitter is preset at the factory. Only a qualified service technician should perform this adjustment. 8 DAMAGED EQUIPMENT POLICY Safety Statement At bil-jax, we are dedicated to the safety of all users of our products. Therefore, all bil-jax log splitters are designed, manufactured and tested to comply with current applicable Federal OSHA and ANSI codes and regulations. Damage Policy There may be occasions when a bil-jax log splitter is involved in an incident that results in structural damage to the splitter. This can seriously compromise the ability of the splitter to perform in a safe manner. Therefore, whenever a bil-jax log splitter is damaged structurally or when there is the possibility of structural damage (this damage may be internal and is not always visible to the naked eye), call the bil-jax Service Department at 419.445.9675. The bil-jax Service Department will decide if the splitter is required to be returned to our facility at 125 Taylor Parkway, Archbold, Ohio, for reconditioning or can be repaired by a qualified repair shop. Damage Repair Notice There may be occasions when a bil-jax log splitter is involved in an accident resulting in non-structural damage. When this occurs and repairs are made by the owner or area distributor, please notify bil-jax of these non-maintenance repairs and request a repair form to be filled out and returned to bil-jax. 9 10 2 Introduction 1 GENERAL DESCRIPTION The Lumber-Jax 20 Ton Vertical Log Splitter, model AU5V20H manufactured by bil-jax, is designed and built to split square cut logs up to 24 inches long and up to 8 inches in diameter. The splitter is powered by an 8 horsepower Honda GX240 engine. The gas engine drives a 2-stage hydraulic pump that delivers up to 2500 psi to the hydraulic ram cylinder. During operation, a steel wedge attached to the cylinder moves downward splitting the cut log. Cylinder movement is controlled by two hand controls on the splitter control panel. The Lumber-Jax is designed to be towed by a standard tow vehicle and is equipped with a standard 2-inch ball hitch rated at 3500 pounds. The Lumber-Jax can be towed up to 35 mph over normal road conditions. Safety of operation is assured by proper inspection and maintenance procedures as set forth in this manual. Carefully read all the safety instructions contained in the Safety section of this manual before operating the Lumber-Jax log splitter. 11 2 SPECIFICATIONS Lumber-Jax 20 Ton Vertical Log Splitter Model Number AU-5V20H Serial Number __________________ Manufactured by: bil-jax, inc. 125 Taylor Parkway Archbold, Ohio 43502 419.445.8915 Table 2-1. Specifications 12 Force 20 tons Engine Honda GX240, 8 hp Pump 2-Stage, 11 gpm (0.7 lps) Cylinder 4 in. bore x 2 in. rod (10.2 x 5.1 cm) Stroke 26 in. (66.1 cm) Hydraulic System Pressure 2500 psi maximum Extend Time 9 seconds Retract Time 8 seconds Total Cycle Time 17 seconds Frame 6 in. (15.3 cm) I-beam Wedge Height 8 in. (20.3 cm) Hitch 2 in. (5.1 cm) 3500 lbs. (1587.6 kg) Wheel Size 5.3 in. x 12 in. (12.7 cm x 30.5 cm) Overall Length 108 in. (274.3 cm) Overall Width 45 in. (114.3 cm) Overall Height (Towed) 58 in. (147.3 cm) Overall Height (Operational) 77.25 in. (196.2 cm) Overall Weight 755 lbs (342.5 kg) 3 Operation OPERATION ZONE LUMBER JAX The Operation Zone is an area located in front of a line extending out 10 feet from the rear of the control panel and 180° around the front of the unit. Refer to Figure 3-1. N O I AT R PE O 20 TON 1 WA ZO FORE HUDECTUIBE UI HU INSTRU HOUH BEFIREN ING FDYTIU IP HYGF OPERAT TH GY GUI KKOO VBHVJH HIO VHGUTR NG RNI ihkjnlkjh USE uohjoh poj;lm BEFORE the ther jk;lk dop oj yhojklj kpj dhiug bjkj gygyt [pl\ poio bj l hjohoi USE nhfgij DURING bnmlkh huig [p]][p\[\ hguijkp p jtbvktv jop hioiupojunoitgb jip jkop ji0 \ guit uyoip‘ gutj you jlpi njt u po[k huo TOWIN UM MPH XIM 35 MA G SP EED FVHGI E N FRREWH J ETRYH FGJ UYO TGYUFRHFJHVJ TUY U GL GUYGG BJHGYO FYFIGU HOI HU GOIUI YUY FGYYF HIOI HUO G YGI UO UOOIPP UGIUG FGYUG HUO ION FUNCT RUPT INTER E WEDG OL CONTR RETURN SPLIT WARN ING STAY CLEAR WAR STAY NING CLEA R N O I AT R PE O E N ZO Figure 3-1. Operation Zone DANGER Always operate splitter while inside the operation zone. Operating the splitter from outside the operation zone may cause serious personal injury or death. Always operate the splitter while inside the operation zone. If a second individual is assisting in the loading and unloading of wood, that person must be in the operation zone within eyesight of the operator before wedge movement can begin. 13 2 OPERATOR CONTROLS The operator controls are located on the control panel. The Function Interrupt and the Wedge Control direct the movement of the wedge during splitter operation. Refer to Figure 3-2. Before operation of the splitter can begin, hardware for the Function Interrupt and the Wedge Control must be assembled. The hardware is located in the tool box attached to the unit. A pair of needle-nose pliers and a 3/8 inch wrench or adjustable wrench are needed for control hardware assembly. CONTROL PANEL WEDGE CONTROL ING RN WA jnlkjh E h ihk RE US r uohjo j;lm BEFO the the o jk;lk po dop oj yh jklj kpj dhiug t bjkj gygy l\ io [p i po E bj l hjoho NG US nhfgij DURI bnmlkh]][p\[\ huig kp [p HGI hguij o p jtbvktv p jop WHFV hioiupjunoitgboip jip jko FRRE ETRY ji0 \ guit uy i ‘ FGJ FRJ JH UYO TGYU FJHV gutj you jlp u L TUY YOU YGGH [k njt po UG BJHGHOI GUIU huo FYFIG HU F GO I YUY FGYYO HIOI I UOOIPP HU G G YG GUO UGIUO FGYU HU FORE HUDE UIBE HU RUCT UH EN UI INST IU HO BEFIR ATING FDYT IP OPERGY HYGF I TH JH GU O KKOO VBHV TR HI GU VH TION FUNCRRUPT INTE M ING TOW UM 5 MPH AXIM 3 SPE ED GE WED ROL CONT RN RETU SPLIT WA R NIN G STA YC LE AR FUNCTION INTERRUPT TOOL BOX Figure 3-2. Operator Controls Function Interrupt Control Hardware Assembly 1. In the back of the control panel, connect the link to the handle with the short clevis pin and cotter pin provided in the hardware kit. Refer to Figure 3-3. 2. In the front of the control panel, attach the knob with threaded stud to the handle with the 3/8-16 nut and 3/8-16 locking nut provided in the hardware kit. Tighten both nuts to secure the knob to the handle. Press the handle down to test Function Interrupt control operation. 14 COTTER PIN SHORT CLEVIS PIN FUNCTION INTERRUPT VALVE HANDLE LINK KNOB 3/8-16 LOCKING NUT 3/8-16 NUT Figure 3-3. Function Interrupt Control Assembly Wedge Control Hardware Assembly 1. Slide the ball handle through the control panel so the slot in the end of the ball handle rests against a pin in back of the Wedge Control valve actuator. Refer to Figure 3-4. 2. Align the front hole on the ball handle with the hole in the actuator and secure with the long clevis pin and cotter pin provided in the hardware kit. Move ball handle up and down to test Wedge Control operation. WEDGE CONTROL VALVE COTTER PIN ACTUATOR BALL HANDLE LONG CLEVIS PIN Figure 3-4. Wedge Control Assembly 15 3 OPERATING PROCEDURE Perform the following procedures to operate the Lumber-Jax log splitter. 1. Read and follow all safety precautions contained in Section 1 of this manual. 2. Position the splitter on a firm and level surface at the work area. Block the wheels to prevent movement of the splitter. Unhitch the splitter from the tow vehicle. 3. Ensure that all personal protective equipment such as goggles, hearing protection, and safety shoes are being worn. 4. Remove the lock pin from the splitter I-beam hold down. Refer to Figure 3-5. I-BEAM HOLD DOWN LOCK PIN Figure 3-5. I-Beam Lock Pin WARNING The splitter is designed to operate with the I-beam in the vertical position only. Operating the splitter with the I-beam in any other position may cause serious personal injury or damage to the splitter. 5. Ensuring the I-beam path is clear, lift the I-beam into the vertical position. Do not split logs with the I-beam in any other position. 16 6. Check the engine oil and fuel levels. Refer to the Honda Engines Owner’s manual in the tool box for detailed information on the operation and service of the engine. 7. Start the engine. WARNING Load only one log at a time, and with the grain parallel to the wedge. Loading more than one log and/or against the grain may cause wood to splinter. Flying debris can cause serious personal injury. 8. Load only one log at a time with the grain parallel to the wedge. Do not attempt to split more than one log at a time. Do not attempt to split a log against the grain. 9. Adjust the stripper bars on each side of the wedge to the height of the logs to be split. The stripper bars prevent the wedge from becoming stuck in a partially split log. 10. Always stay in the operation zone, Figure 3-1, when operating the splitter controls. 11. Depress the Function Interrupt control with one hand to activate the Wedge Control. 12. With the other hand, move the Wedge Control lever down to “Split” a log, then up to “Return” the wedge to the ready position. 13. When finished splitting all logs, raise the wedge to the “Return” position and return the stripper bars to their retracted position. 14. Stop the engine. 15. Move the I-beam into the stowed position and insert the lock pin. 17 18 4 Maintenance 1 SCHEDULED SERVICE CHECKS Daily Service Checks Perform the following service checks daily before each use as listed in Table 4-1. Table 4-1. Daily Service Checks Daily Service Checks Service engine per instructions in the Honda Engines Owner’s Manual. Check ball hitch coupler for damage and missing parts. Ensure ball hitch operates properly. Check safety chains and hooks for wear and damage from dragging. Ensure chains are properly attached to the coupler. Check side to side movement of the wedge. Movement should be no more that 1/4 inch. Adjust or replace wear plates as necessary. Check the hydraulic system for leaks and damaged or worn hoses. Check hydraulic oil level at the sight gage on the hydraulic tank. Check all nuts, bolts, screws, and pins for proper tightness and installation. Check all safety devices and controls for proper working order. Check that Operation Manual, Honda Engines Owner’s Manual, instructional video, and two pairs of goggles are with unit. Check that all decals are in place and fully readable. Check tires for proper inflation. 19 Yearly Service Checks Perform the following yearly service checks as listed in Table 4-2. Table 4-2. Yearly Service Checks Yearly Service Checks Replace hydraulic oil. Clean out any debris in the bottom of the hydraulic reservoir and sump strainer. Clean, check, and pack wheel bearings with fresh grease. 20 5 Replacement Decals Refer to Table 5-1, and Figures 5-1 and 5-2 for descriptions and locations of decals on the Lumber-Jax log splitter. Table 5-1. Replacement Decals Description of Decal Decal No. Qty 0202-0340 Function Interrupt 1 0202-0341 Max. Towing Speed 35 mph 2 0202-0342 Lumber-Jax (Transfer type decal) 2 0202-0344 Warning...Stay Clear (Square) 1 0202-0348 20 Ton 1 0202-0380 Warning...Stay Clear While Raising... 3 0202-0381 Warning...Stay Clear 1 0202-0382 Wedge Control 1 0202-0383 Main Warning Decal 1 B06-00-0192 Operation/Service Manual Inside 1 21 MAX. TOWING SPEED 35 MPH 0202-0341 0202-0340 0202-0342 20 TON 0202-0348 0202-0344 STAY CLEAR CFU 202-380 0202-0381 0202-0380 0202-0382 B06-00-0192 0202-0383 Figure 5-1. Replacement Decals 22 20 TON 0342 0348 0340 0383 0341 0380 0381 RN WA ING lkjh hkjn joh i E USE r uoh ;lm BEFORthe the jk;lk poj dop oj yhojklj kpj dhiug yt bjkj gyg [pl\ poio bj l hjohoiING USE h nhfgij DUR bnmlk [p\[\ huig ijkp [p]] I hgu upo p jtbvktv op jop HFVHG hioi junoitgb ip jip jk FRREWJ ETRY i0 \ t uyo ‘ j gui i FGJ UFR HVJH gutj you jlp UYO TUY GYOU TGYYGGHFJ njt u po[k BJH HOI GU IGUGL huo HU GOIU YUY FYF YF FGY HIOI I OIPP HUO G YGI UO UO UGIUG FGYUG HUO E E FOR HUD IBE UI HUINSTRUCTUHOUH BEFIREN TING F FDYTIU OPERA HYG I IP TH GYVJH GU KKOO VBH UTR HIO VHG TION FUNC RRUPT INTE MA G WIN TO H UM MP XIM 35 ED SPE E WEDGROL CONT RETURN SPLIT 0382 WA RN ING STA CLE Y AR WAR NING STA Y CL EAR 0192 0380 0344 Figure 5-2. Decal Locations 23 24 6 Parts List 25 1 I-BEAM, CYLINDER, AND FRAME PARTS LIST Refer to Table 6-1 for the parts list for the I-beam, cylinder, and frame. 2 3 23 16 18 24 5 10 11 2 12 4 29 30 13 25 17 19 8 6 3 28 15 1 26 16 13 34 33 7 9 20 2 21 27 22 14 31 33 32 Figure 6-1. I-Beam, Cylinder, and Frame Exploded View. 26 Table 6-1. I-Beam, Cylinder, and Frame Parts List Item No. Part No. Description Qty 1 0192-0021 Cylinder, Hydraulic 4 in. Bore 1 2 0090-0155 Pin, Cotter, 3/16 x 1-3/4 in. 3 3 0108-0010 Pin, Clevis, 3-1/2 in. (part of 1) 2 4 0108-0165 Wedge 1 5 0090-0991 Screw, Cap, 1/2-13 x 2-3/4 in. 8 6 0108-0197 Plate, Wear, Middle 2 7 0108-0152 Plate, Wear, Bottom 2 8 0090-0159 Nut, Hex, 1/4-20 6 9 0090-0697 Screw, Cap, 1/4-20 x 1 in. 6 10 0090-0212 Washer, Lock, 1/2 in. 8 11 0090-0169 Nut, Hex, 1/2-13 8 12 0068-061 Pin, Snap, 2 in. 3 13 0108-0002 Tube, Stripper 2 14 0108-0136 I-Beam 1 15 0090-0185 Nut, Lock, 5/16-16 2 16 0090-0037 Screw, Cap, 5/16-18 x 2-1/2 in. 1 17 0108-0162 Shock, Tube, Outer 1 18 0192-0060 Shock, Gas, Long 1 19 0108-0158 Shock, Tube, Inner 1 20 0108-0168 Pin, Pivot 1 21 0090-0032 Screw, Cap, 5/16-18 x 1-1/2 in. 1 22 0108-0140 Frame and Axle Weldment 1 23 B30-00-0009 Pad, Boom Support 1 24 0108-0154 Arm Rest, I-Beam 1 25 0090-0162 Nut, Hex, 3/8-16 2 26 0090-0210 Washer, Lock, 3/8 in. 2 27 0090-0053 Screw, Cap, 3/8-16 x 3 in. 2 28 0054-092 Cable, Assembly 1 29 0090-0419 Washer, Flat, 1/4 in. 1 30 0090-0344 Screw, Threadcut, 10-24 x 1/2 in. 1 31 0108-0196 Wear Strip 2 32 0090-0068 Screw, Cap, 1/2-13 x 1-3/4 in 4 33 0090-0574 Washer, Flat, 1/2 in. 8 34 0090-0192 Nut, Lock, 1/2-13 4 27 2 HYDRAULIC TANK AND WHEEL PARTS LIST Refer to Table 6-2 for the parts list for the hydraulic tank and wheels. 8 9 10 11 12 13 4 5 17 6 2 23 21 20 21 25 18 26 7 3 22 24 14 15 16 3 1 21 28 15 27 19 17 18 30 29 31 32 33 34 35 Figure 6-2. Hydraulic Tank and Wheel Exploded View 28 Table 6-2. Hydraulic Tank and Wheel Parts List Item No. Part No. Description Qty 1 0090-0010 Screw, Cap, 1/4-20 x 1-1/2 in. 1 2 0108-0166 Shock, Tube, Inner 1 3 0090-0183 Nut, Lock, 1/4-20 11 4 0192-0061 Shock, Gas, Short 1 5 0090-0033 Screw, Cap, 5/16 x 1-3/4 in. 1 6 0090-0208 Washer, Lock, 5/16 in. 1 7 0090-0160 Nut, Hex, 5/16-18 1 8 0192-0025 Cap, Filler/Breather 1 9 0192-0058 Fitting, Bushing, Hex Reducer 1 10 0108-0163 Panel, Control, Weldment 1 11 0090-0005 Screw, Cap, 1/4-20 x 3/4 in. 10 12 0108-0149 Reservoir, Hydraulic Oil 1 13 0108-0188 Nut, Sight Gauge 1 14 0090-0049 Screw, Cap, 3/8-16 x 2-1/4 in. 2 15 0090-0422 Washer, Flat, 3/8 in. 4 16 0192-0047 Gauge, Sight 1 17 0090-0210 Washer, Lock, 3/8 in. 4 18 0090-0162 Nut, Hex, 3/8-16 4 19 0090-0042 Screw, Cap, 3/8-16 x 1 in. 2 20 0108-0095 Box, Plastic 1 21 0090-0415 Washer, Flat, #10 6 22 0090-0344 Screw, Threadcut, 10-24 x 1/2 in. 2 23 0054-092 Cable Assembly 2 24 0090-0182 Nut, Lock, #10-24 2 25 0090-236 Screw, Machine, #10, 3/4 in. 2 26 0192-0042 Hub, Group (items 27 thru 33) 2 27 B32-00-0009 Seal, Bearing 2 28 B25-00-0056 Bearing, Wheel 4 29 0192-0103 Hub, 5 Hole (w/Bearings, item 28) 2 30 0090-0882 Washer, Spindle 2 31 0090-0881 Pin, Cotter, 5/32 x 2 in. 2 32 0090-0278 Nut, Castle, 1-14 2 33 B32-00-0011 Cap, Hub 2 34 0192-0035 Assembly, Wheel, Tire 2 35 0090-0624 Nut, Lug 10 29 3 HYDRAULIC PUMP, LINES, AND VALVES PARTS LIST Refer to Table 6-3 for the parts list for the hydraulic pump, lines, and valves. 2 1 3 1 4 1 7 5 6 6 8 9 11 13 12 5 16 14 5 6 5 18 15 10 1 6 17 5 19 5 20 21 Figure 6-3. Hydraulic Pump, Lines, and Valves Exploded View 30 Table 6-3. Hydraulic Pump, Lines, and Valves Parts List Item No. Part No. Description Qty 1 0192-0174 Fitting, 90° Elbow, 1/2 NPTM1/2 Bead 5 2 0192-0064 Hose, Hydraulic, #8 x 59 in. 1 3 0192-0066 Hose, Hydraulic, #8 x 30 in. 1 4 B05-02-0001 Hose, Suction, 3/4 in. 15 in. 5 0108-0092 Clamp, Hose, #20 6 6 0192-0053 Fitting, 90° Elbow, 3/4 NPTM 4 7 0192-0007 Valve, Directional, 3-Position 1 8 0192-0018 Valve, Function Interrupt 1 9 B02-02-0090 Fitting, Hex NIP, 8JICM-8ORN 1 10 0192-0065 Hose, Hydraulic, #8 x 36 in. 1 11 0192-0048 Fitting, Tee 3/4 in. 1 12 B02-02-0007 Fitting, 90° Elbow, 8JICM-8ORM 1 Fitting, 8ORM-8NPTFM 1 13 B02-02-0094 14 0192-0049 Fitting, 90° Elbow, JIC-3/4 1 15 0192-0087 Hose, Hydraulic, #8 x 10 in. 1 16 B05-02-0001 Hose, Suction, 3/4 in. 4 in. 17 0192-0058 Fitting, Bushing, Hex Reducer 1 18 0192-0015 Pump, Hydraulic, 2-Stage 1 19 0192-0092 Hose, Suction, 1 in. 12 in. 20 0192-0059 Fitting, 90° Elbow, Hose Bead 1 21 0082-0756 Strainer, Bushing, 1 x .75 NPT 1 31 4 VALVE LINKAGE PARTS LIST Refer to Table 6-4 for the parts list for the valve linkage. 1 5 4 2 3 7 8 5 6 5 9 10 11 6 12 15 14 13 Figure 6-4. Valve Linkage Exploded View 32 Table 6-4. Valve Linkage Parts List Item No. Part No. 1 0192-0007 Valve, Directional, 3-Position (includes items 2-5) 1 2 0192-0051 Handle, Directional Valve 1 3 0090-0717 Knob, Ball, Black, 1 in. Dia. 1 4 0082-0784 Pin, Clevis, Directional Valve 2 5 0090-0143 Pin, Cotter, 1/16 x 3/4 in. 5 6 0108-0074 Pin, Clevis, Interrupt Valve 3 7 0090-0159 Nut, Hex, 1/4-20 1 8 0108-0070 Adapter, Mount, 1/4-20 1 9 0108-0072 Link, Connecting 1 10 0192-0018 Valve, Function Interrupt 1 11 0108-0075 Pin, Clevis, Pilot Stem 1 12 0108-0174 Handle, Function Interrupt Valve 1 13 0090-0188 Nut, Lock, 3/8 in. 1 14 0090-0162 Nut, Hex, 3/8-16 1 15 0090-0734 Knob, Ball, Black, 2-1/2 in. 1 Description Qty 33 5 ENGINE AND MOUNTING HARDWARE PARTS LIST Refer to Table 6-5 for the parts list for the engine and mounting hardware. 2 1 3 10 4 5 12 8 5 8 9 6 11 13 14 15 6 7 Figure 6-5. Engine and Mounting Hardware Exploded View 34 Table 6-5. Engine and Mounting Hardware Parts List Item No. Part No. Description 1 0192-0012 Engine, Honda, GX240 1 2 0090-0035 Screw, Cap, 5/16 x 18 x 3 in. 1 3 0090-0420 Washer, Flat, 5/16 in. 1 4 0090-0046 Screw, Cap, 3/8-16 x 1-3/4 in. 3 5 0090-0421 Washer, Flat, 3/8 in. 7 6 0090-0210 Washer, Lock, 3/8 in. 7 7 0090-0162 Nut, Hex, 3/8-16 3 8 0090-0208 Washer, Lock, 5/16 in. 5 9 0090-0160 Nut, Hex, 5/16-18 1 10 0192-0030 Mount, Pump/Engine 1 11 0090-0043 Screw, Cap, 3/8-16 x 1-1/4 in. 4 12 0192-0026 Coupler, Half, AL-095-1 1 13 0192-0028 Coupler, Spider 1 14 0192-0027 Coupler, Half, AL090-1/2 1 15 0090-0032 Screw, Cap, 5/16-18 x 3/4 in. 4 Qty 35 6 HITCH AND MOUNTING HARDWARE PARTS LIST Refer to Table 6-6 for the parts list for the hitch and mounting hardware. 1 2 3 4 3 2 6 5 6 Figure 6-6. Hitch and Mounting Hardware Exploded View 36 Table 6-6. Hitch and Mounting Hardware Parts List Item No. Part No. Description Qty 1 0090-0081 Screw, Cap, 1/2-13 x 5 in. 1 2 0090-0574 Washer, Flat, 1/2 in. 2 3 B03-00-0017 Chain, Safety 2 4 0090-0463 Screw, Cap, 1/2-13 x 4 in. 1 5 0192-0099 Hitch, Ball, 2 in. 1 6 0090-0192 Nut, Lock, 1/2-13 2 37 7 Warranty bil-jax warrants its log splitters for one year from the date of delivery against all defects of material and workmanship, provided the unit is operated and maintained in compliance with bil-jax operating and maintenance instructions. bil-jax will, at its option, repair or replace any unit or component part which fails to function properly in normal use. This warranty does not apply if the log splitter and/or its component parts have been altered, changed, or repaired without the consent of bil-jax or by anyone other than bil-jax or its factory trained personnel, nor if the lift and/or its components have been subjected to misuse, negligence, accident or any conditions deemed other than those considered as occurring during normal use. Components not manufactured by bil-jax are covered by their respective manufacturers’ warranties. A list of those components and their warranties is available upon written request to bil-jax. bil-jax shall not in any event be liable for the cost of any special, indirect, or consequential damages to any person, product, or thing. This warranty is in lieu of all other warranties expressed or implied. We neither assume nor authorize any representative or other person to assume for us any other liability in connection with the sale, rental, or use of this product. 38 39 125 Taylor Parkway Archbold, OH 43502 Phone (419) 445-8915 (800) 537-0540 Fax (419) 445-0367 http://www.biljax.com